Cooling system and method

ABSTRACT

The present invention related to cooling systems. More specifically, the present invention relates to a system for cooling one or more parts of a building and or processes comprising a compressor, a condenser having an inlet and an outlet and a plurality of condenser cooling fans, a receiver, a liquid refrigerant pump, an expansion device, an evaporator, the evaporator being surrounded by a chiller barrel having a cooled water return and a chilled water supply line, and refrigerant line means interconnecting the compressor, condenser, expansion device and evaporator in series, in a closed loop for circulating refrigerant therethrough; means for switching the cooling system between free cooling and mechanical cooling and means for actively floating the head pressure in both mechanical and free cooling modes.

FIELD OF THE INVENTION

The present invention relates generally to cooling systems and methods.More specifically, the present invention relates to a system and methodfor the active and passive cooling of buildings or certain processesthat are located in cooler climates with high heat loads.

BACKGROUND OF THE INVENTION

Vapor compression refrigeration systems are well known in the art. Vaporcompression systems circulate refrigerant to achieve a desired coolingeffect. Starting with the evaporator, which is where the desired coolingeffect is achieved, refrigerant evaporates, thereby carrying away thelatent heat of vaporization, as it passes through the evaporator. Theevaporator serves as a heat exchanger. Air, water, glycol or othercooling mediums, which are hereinafter referred to interchangeably as“water” or “secondary fluids,” forced over the surface of the evaporatorare cooled. At the same time, the evaporator surface is warmed, therebycontinuing the vaporization of the refrigerant.

Refrigerant leaving the evaporator is in a low pressure gas state. Thislow pressure refrigerant is then compressed by a compressor to a hot,highly pressurized gas state and passed to yet another heat exchanger,the condenser, which is normally outside, or a distance away from, theobject or building being cooled. The condenser provides a locationwherein the hot refrigerant is permitted to condense to a liquid. Thisresults in heat transfer from the refrigerant to cooler surroundings.After passing through the condenser, the liquid refrigerant enters theexpansion valve where it again expands to the evaporator pressure.

As most people are aware, air conditioning is used to cool buildings inthe warm summer months. However, many buildings also require mechanicalcooling during the winter months as well. This is due to high internalheat loads that are generated by processes, persons, lighting, computersand other office equipment situated within the building. Other buildingsthat have high internal heat loads often house factory equipment. If thebuilding has no means to bring in outside air to cool the building, thenenergy intensive mechanical cooling systems must be operated.

Typical mechanical cooling systems are generally designed to run duringthe warmer months of the year. If a mechanical cooling system isrequired to operate during very cold weather, the system will oftenfail. Such failures normally occur at temperatures below 32 degreesFahrenheit. In general, this failure is caused by the refrigerant havinga tendency to migrate to the coldest spot in the cooling system,normally the condenser, which is located outside. As a result, thecompressor starves for refrigerant and is automatically shut down on lowevaporator pressure.

One way to keep the compressor running in the foregoing situation is toemploy a liquid refrigerant pump after the condenser to pump liquidrefrigerant to the expansion device. The use of a refrigerant pump asdescribed will also eliminate flash gas in the outlet lines leading tothe expansion valve. This permits the compressor to run at lowerdischarge pressures and temperatures, thereby saving energy by takingthe load off the compressor. However, such methods may not be asefficient for buildings and processes that require cooling on very colddays. Therefore, what is needed is a cooling system and method that iseffective on cold days and that does not require the inefficient, powerintensive use of mechanical cooling.

SUMMARY OF THE INVENTION

A preferred embodiment of the system and method of the present inventionprovides for an extremely efficient hybrid mechanical cooling or “free”cooling, air conditioning system. The cooling system disclosed permitsthe floating of head pressure with mechanical cooling thereby providingsubstantial energy savings. The same cooling system permits freecooling, that is the compressor is bypassed and liquid refrigerant iscirculated through the cooling system by a liquid refrigerant pump.

In free cooling mode, the cooling system is capable of being powered bya solar array, small wind turbine or micro hydro power source. In freecooling mode, the cooling system could optionally operate off theconventional electric grid 100% of the time.

A preferred embodiment of the present invention also provides forprogrammable control of the condenser fans. The cooling system mayprovide for the use of digital control for automatic transitions betweenfree cooling and mechanical cooling.

Yet another feature of the cooling system is the use of automated ballvalves as opposed to solenoid valves to control changeovers between freecooling and mechanical cooling. The use of ball valves reduces oreliminates instances of leak by. Additionally, solenoids have nopositive closure. Ball valves also offer substantially lower pressuredrops, thereby increasing the efficiency of the cooling system.Additionally, automated ball valves are capable of offering precisefeedback as to position.

Another embodiment of the invention operates without the use of anexpansion device in the free cooling mode.

Another embodiment of the invention provides for the use of a receiveras a liquid vapor trap following the condenser. Such a device storesliquid refrigerant downstream from the condenser, thus increasingcondensing space.

A preferred embodiment of the present invention provides for a liquidrefrigerant pump having a soft start mechanism to reduce the likelihoodof decoupling under cold refrigerant conditions. An additionalembodiment of the invention may provide for a flat plate heat exchangerbetween the outlet of the liquid refrigeration pump and the expansiondevice. The flat plate heat exchanger could potentially be attached toan external cool water source such as well water, pond, ice storagedevice or geothermal source.

A preferred embodiment of the present invention may employ a watercooled condenser using liquid refrigerant injection. The liquidrefrigerant injection de-superheats the vapor leaving the compressor toreduce the temperature of the vapor entering the water cooled condenser.Liquid refrigerant injection can prevent the formation of scale therebymaintaining the efficiency of the heat exchanger.

The cooling system of the present invention is capable of operating infree cooling mode at temperatures as high as 60 degrees F. Additionally,a preferred embodiment of the present invention may be operable incombination with a second or multiple cooling systems. In an exemplaryinstallation, two chillers are required for cooling in the warmermonths. Both chillers may be capable of floating head pressure. Incooler weather, however, such chillers may not operate as efficiently.Such systems may shut down one chiller under certain conditions andsimply run one chiller under free cooling conditions.

As indicated, the preferred embodiment of the present invention isdesigned to improve the efficiency of refrigeration and air conditioningsystems in cool weather. The preferred embodiment also enables theaforementioned improvements in efficiency economically and byretrofitting existing systems as well as new systems.

The foregoing and other features of the system and method of the presentinvention will be apparent from the detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a prior art cooling system.

FIG. 2 is a schematic diagram of the cooling system claimed in theappended claims.

FIG. 3 is a schematic diagram of a number of potential alternativeembodiments to the cooling system claimed in the appended claims.

FIG. 4 shows a flow chart detailing the control logic followed by thecooling system controller used with the system and method of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1 there is illustrated a prior art cooling systemthat circulates refrigerant throughout. The refrigerant may be anysuitable vaporizable refrigerant. The cooling system 1 of FIG. 1 iscomprised of a compressor 2. The compressor 2 compresses the refrigerantfrom a warm vapor state to a hot, highly pressurized state. Therefrigerant is discharged along the compressor/condenser line 4. Therefrigerant moves to the condenser 12, which is normally locatedoutdoors. The condenser 12 is a heat exchanger within which therefrigerant is allowed to condense to a liquid. Condenser fans 14 arethen used to draw heat away from the condenser 12. The liquidrefrigerant exits the condenser 12 via the condenser/expansion deviceline 20, and flows through an expansion device 48 to the evaporator 50.Water, or some other suitable liquid, is circulated through the chillerbarrel 51 via the chilled water return pipe 54 and the chilled watersupply pipe 56. The liquid refrigerant then exits the evaporator 50 viathe evaporator discharge line to the compressor 2.

Such systems are designed to run in the warmer months of the year.However, when temperatures cool, such systems often fail, as therefrigerant used tends to migrate to the coldest area of the system.Normally, during cooler months, the condenser 12 is the coldest part ofthe system, as it is normally located outdoors and in the elements. As aresult, the compressor 2 starves for refrigerant and shuts down as aresult of low suction pressure.

As depicted in FIG. 2, a preferred embodiment of the cooling systemprovides a standard cooling cycle consisting of a closed loop systemhaving a compressor 2, condenser 12, expansion device 48 and evaporator50, each of the aforementioned being connected by refrigerant lines 4,16, 24, 32, 52, 64. A preferred embodiment of the cooling system FIG. 2further provides for a receiver 22 following the condenser 12 and aliquid refrigerant pump 30 following the receiver 22.

The receiver 22 is generally situated lower than the outlet of thecondenser 12, which creates a refrigerant vapor trap. This serves anumber of purposes. First, the receiver 22 prevents vapor from reachingthe liquid refrigerant pump 30, which is not designed to be a vaporpump. Second, the receiver 22 eliminates the need for a critical chargeof refrigerant. Third, the receiver 22 permits the flow of refrigerantout of the condenser 12, thereby freeing up space within the condenser12.

Liquid refrigerant leaving the receiver 22 travels to the liquidrefrigerant pump 30 via the receiver/liquid refrigerant pump line 24.Between the receiver 22 and the liquid refrigerant pump 30 is a liquidlevel sensor 26. If no liquid refrigerant is detected, the liquid levelsensor 26 sends a signal to a pre-programmed controller 180 which iscapable of deactivating the liquid refrigerant pump 30. In the eventthat no liquid refrigerant is detected for a set period of time, a leakcondition is assumed and the controller 180 activates an alarm. Thespeed of the liquid refrigerant pump 30 is adjustable via preprogrammingof the controller 180 such that the refrigerant flow can be varied.

The cooling system FIG. 2 employs a liquid refrigerant pump 30 that isused to pump liquid refrigerant between the condenser 12 and theevaporator 50. When the compressor 2 runs, this allows the compressor 2to run at lower temperatures and pressures. A subject which will bediscussed in more detail later. The refrigerant pump 30 used with thepresent invention employs a magnetic driven impeller pump. Magneticdrive pumps are seal-less pumps that use a coaxial magnetic coupling totransmit torque to an impeller. An electric motor drives a set ofpermanent magnets that are mounted on a carrier or drive assembly. Inturn, the magnets drive the inner rotor and provide the no-slip orsynchronous capability of the torque coupling. The refrigerant pump 30also employs a soft start sequence to avoid decoupling between themagnet and the impeller.

In the event that the electric motor or the liquid refrigerant pump 30fails, a preferred embodiment of the present invention provides for abypass loop 34 around the liquid refrigerant pump 30. The bypass loop 34contains a differential check valve 36. The liquid refrigerant pump 30pumps refrigerant to the expansion device 48 via liquidrefrigerant/expansion device line 32.

A preferred embodiment of the present invention employs a ball valve 46in series with the expansion valve 48. Additionally, a preferredembodiment provides for a bypass loop 38 around the expansion valve 48.Each of the ball valves 42, 46 has feed-back capabilities for reportingposition and sequence to the controller 180.

In some circumstances, it may be advantageous to bypass the expansiondevice 48 via the expansion device bypass line 38. In that case, themechanical ball valve 42 is “open.” In the event the expansion device isin use, e.g. when the compressor 2 is running, the ball valve 42 on theexpansion device bypass line 38 is “closed” and the ball valve 46preceding the expansion device 48 is “open.” Refrigerant passing througheither the expansion device 48 line or the expansion device bypass line38 enter the evaporator 50. The evaporator 50 is surrounded by thechiller barrel 51. Water from the chilled water return line 54circulates through the chiller barrel 51 and returns to the object beingcooled via the chilled water supply line 56. Heat exchange between thecold refrigerant and the secondary fluid (as mentioned above, air,water, liquid refrigerant, glycol, citrus based cooling fluids or othercooling mediums, are hereinafter referred to interchangeably as “water”or “secondary fluids,”) in the chiller barrel 51 cools the water in thechiller barrel 51.

Refrigerant exiting the evaporator 50 via the evaporator/accumulatorline 52 enters the accumulator 58. A preferred embodiment of the coolingsystem FIG. 2 employs a suction line accumulator 58 to capture anyliquid refrigerant not evaporated in the evaporator 50 ahead of thecompressor 2. The preferred embodiment of the cooling system FIG. 2 alsoincludes a liquid refrigerant sensor 60 on the evaporator/accumulatorline 52. The liquid refrigerant sensor 60 is in electronic contact withthe controller 180. If liquid refrigerant is sensed, the controller 180will not permit the compressor 2 to start.

The compressor 2 is effectively isolated using three ball valves 70, 74,6. The suction line accumulator ball valve 70 is located on theevaporator/accumulator line 52. The compressor discharge ball valve 6 islocated downstream of the compressor 2. The compressor bypass ball valve74 is located on the compressor bypass line 72. Each of the three ballvalves 70, 74, 6 have feedback capability and provide position feedbackto the controller 180. If any of the ball valves 70, 74, 6 are out ofposition, the controller 180 will not start the compressor 2. Thecompressor bypass line 72 also has a check valve 76 to prevent hot,compressed refrigerant from flowing back through the compressor bypassline 72. Line 80 is used to vent crankcase vapor.

When mechanical cooling is not required, i.e., when the compressor 2 isoff, the controller 180 shuts off a compressor crankcase heater (notshown) to save energy. When the controller 180 determines thatmechanical cooling may be required, the controller 180 turns on thecrankcase heater well in advance of the compressor start sequence.

A preferred method of operation for free cooling is that when the glycolchilled water temperature in the chiller barrel 51 increases above anadjustable predetermined point, e.g. 45 degrees F., and the outsidetemperature is below an adjustable predetermined point, e.g. 40 degreesF., and it is one of a predetermined set of cooler months, the coolingsystem FIG. 2 will automatically switch to free cooling mode. However,before energizing the free cooling loop, the controller 180 identifieswhether the chilled water pumps are on, whether the chiller is activeand whether the building is occupied.

If these conditions are met, the controller 180 will isolate thecompressor 2 by closing the compressor suction line ball valve 70 andthe compressor discharge line ball valve 6 and opening the ball valve 74on the compressor bypass line 72. The controller 180 also directs theexpansion line ball valve 46 to close, thereby closing off the expansiondevice 48. Refrigerant bypasses the expansion device 48 and enters theevaporator 50 inside the chiller barrel 51 where the refrigerant picksup heat from the circulating glycol chilled water from the building. Therefrigerant, being in a mixed vapor and liquid state, enters theevaporator/accumulator line 52 and then the compressor bypass line 72.The refrigerant then bypasses the compressor 2 and moves directly to thecondenser 12, where it cools as it gives up heat to the outside air,geothermal source, pond, well or ice storage unit. Each of theabove-referenced ball valves 6, 70, 74, 42, 46 is equipped with acircuit or controller that communicates the physical position of thevalves 6, 70, 74, 42, 46 to the controller 180.

Once the position of each ball valve 6, 70, 74, 42, 46 has beenverified, a liquid level sensor 26 verifies that there is sufficientliquid refrigerant in the receiver/refrigerant pump line 24 before thefrequency drive or soft start means for the liquid refrigerant pump 30is energized. The liquid refrigerant pump 30 is then slowly ramped up tooperating speed. Some embodiments of the invention may includeadditional means for protecting the liquid refrigerant pump 30 fromstarvation. For example, a flow sensor could be positioned eitherupstream or downstream from the liquid refrigerant pump 30, or both.Additionally, a pressure sensor could be used upstream and/or downstreamfrom the liquid refrigerant pump 30.

A temperature sensor 10 is located on the compressor/condenser line 4.Another temperature sensor 18 is located on the condenser/receiver line16. Each of the temperature sensors 10, 18 is in electroniccommunication with the controller 180 as well. The controller 180follows a pre-programmed algorithm to determine the speed at which toset the condenser fans 14. The refrigerant temperature is normally setat a specific temperature, e.g. 30 degrees F. and is maintained by thecontroller 180. As the refrigerant increases or decreases intemperature, the controller 180 responds by increasing or decreasing thespeed of the condenser fans 14. If and when the chilled water leavingthe chiller barrel 51 reaches a certain desired set-point temperature,the liquid refrigerant pump 30 and the condenser fans 14 are shut off.When the chilled water temperature leaving the chiller barrel 51 reachesa desired set-point temperature, e.g. 45 degrees F., the liquidrefrigerant pump 30 and condenser fans 14 are reactivated.

When required, the same cooling system can be reconfigured formechanical cooling. When the glycol chilled water temperature increasesabove an adjustable set point, e.g. 45 degree F., and the outside airrises above an adjustable set point, e.g. 40 degrees F., and it is oneof the warmer months of the year, the system switches to mechanicalcooling. Before mechanical cooling can begin, the controller 180 willdetermine whether the chilled water pumps are on and that the buildingis in the occupied mode. At the same time, the controller 180 willdetermine by the liquid sensor 60 whether any liquid is present in line64 before the compressor 2 is permitted to start.

As part of the changeover to mechanical cooling, the system first purgesrefrigerant, i.e., the glycol chilled water is permitted to boil offrefrigerant in the evaporator 50 and second, turns on the compressorcrank case heater. Normally, the refrigerant is simply given anadjustable predetermined amount of time to boil off. The condenser fans14 are then started, thereby cooling the refrigerant in the condenser 12and causing condensation of refrigerant, which reduces pressure in thecondenser 12 and draws refrigerant to the condenser 12.

After the purge cycle is completed, the controller 180 directs the ballvalve 70 on the evaporator/accumulator line 52 to open, the ball valve 6on the compressor/discharge condenser line 4 to open and the ball valve74 on the compressor bypass line 72 to close. Additionally, the ballvalve 42 on the evaporator bypass line 38 is closed. As discussedearlier, each ball valve 6, 42, 46, 70, 74 has positioning feedbackcapability to the controller 180 such that the controller 180 can verifywhether the valves 6, 42, 46, 70, 74 are in the open position before thecompressor 2 starts.

When the compressor 2 cycles on, the liquid refrigerant pump 30 isstarted after an adjustable time delay of, e.g. 30 seconds. Once theliquid refrigerant pump 30 is operating, the head pressure will beallowed to float downwardly to an adjustable set point, e.g. 120p.s.i.g. While the compressor 2 is running, a pressure sensor 78 on thecompressor/condenser line 4 is used to regulate condenser fans 14 speed.When head pressure increases, the speed of the condenser fan 14 will beincreased.

If and when the chilled water temperature leaving the evaporator reachesset point temperature, the compressor 2, liquid refrigerant pump 30 andcondenser fans 14 will shut off. As the chilled water reaches apredetermined set point as recognized by the controller 180, thecompressor 2, liquid refrigerant pump 30 and condenser fans 14 willrestart.

Shown in FIG. 4 is a diagram of the ladder logic employed in controllingand exemplary embodiment of the claimed invention. As has beendiscussed, the building is continually monitored to determine whetherthere is a demand for cooling 110. If there is a demand for cooling 110and if the outside temperature is less than a set point temperature 112,the controller 100 can start the free cooling sequence 114. The freecooling sequence requires a check of the position of each ball valve116, verification that the compressor crankcase heater 118 is turned offand verification that liquid refrigerant is present in theaccumulator/refrigerant pump line 120. If each of the above steps checksout, the liquid refrigerant pump 30 is started 122, the condenser fans14 are started 124 and the glycol supply temperature is monitored tomaintain a desired setpoint temperature 126.

Alternatively, if the building has cooling demand 110 and the outsidetemperature is greater than the specified setpoint temperature 130, themechanical cooling sequence start sequence begins 132. The mechanicalcooling start sequence 132 turns on the compressor crankcase heater 134,verifies the position of each ball valve 136, verifies that there is nopotential for liquid refrigerant to enter the compressor 140. Free coolpurge cycle must report OK 138. In the event each of the steps checksout, the compressor is started 150, the liquid refrigerant pump 152 isstarted, the condenser fans are started 154 and the glycol temperatureis monitored to maintain a desired setpoint temperature 156.

In an exemplary embodiment, a 60 ton chiller that could consume as muchas 60 kilowatts to cool a building may be modified in theabove-described manner to now only consume between 1 and 3 kilowatts. Atthe warmest effective outside ambient temperature, i.e. 40 degrees F.,the “free” cooling circuit can produce 22 tons of cooling capacity usingless than 3 kilowatts. During colder days, this number can exceed 40tons for 3 kilowatts or less total power input.

Having described and illustrated the foregoing cooling system in detail,it should be apparent that the invention can be modified in arrangementand detail without departing from principles thereof.

1. A method for cooling one or more parts of a building and or processescomprising the steps of: providing a compressor, a condenser having aninlet and an outlet, a receiver, a liquid refrigerant pump, an expansiondevice, an evaporator, the evaporator being surrounded by a chillerbarrel having a cooled water return and a chilled water supply line, andrefrigerant line means interconnecting the compressor, condenser,expansion device and evaporator in series, in a closed loop forcirculating refrigerant therethrough; providing a plurality of condenserfans; providing a condenser inlet refrigerant temperature sensor at thecondenser inlet and a condenser outlet temperature sensor at thecondenser outlet; providing a line for the refrigerant to bypass thecompressor; providing a line for the refrigerant to bypass the expansiondevice; monitoring the coolant requirements of the building to determinewhen free cooling is appropriate; bypassing the compressor; bypassingthe expansion device; soft starting the liquid refrigerant pump; andincreasing or decreasing the speed of the condenser fans to maintain aspecific condenser output temperature.
 2. The method of claim 1 whereinthe method may further comprise the step of deactivating the liquidrefrigerant pump and the condensing fans when the chilled water supplytemperature reaches a predetermined set point.
 3. The method of claim 1wherein the step of bypassing the compressor comprises closing amotorized ball valve in the line between the evaporator and thecompressor, closing a motorized ball valve on the compressor dischargeline and opening a motorized ball valve on the compressor bypass line.4. The method of claim 1 wherein the step of bypassing the expansiondevice comprises closing a ball valve on the expansion device line andopening a ball valve on the expansion device bypass line.
 5. The methodof claim 1 further comprising a compressor discharge pressure measuringdevice for measuring head pressure, the discharge pressure measuringdevice being in electronic communication with a controller.
 6. Themethod of claim 5 wherein the controller monitors the head pressure andis capable of varying the speed of the liquid refrigerant pump to varythe flow of liquid refrigerant.
 7. The method of claim 1 wherein themethod for cooling further comprises the step of providing a controllercapable of switching to mechanical cooling when required by closing theexpansion device bypass ball valve; turning on the compressor crankcaseheater; opening the expansion device line ball valve; starting thecondenser fans; waiting an adjustable predetermined time for refrigerantin the evaporator to boil off; opening the compressor input ball valveand the compressor discharge ball valve; closing the compressor bypassball valve; starting the compressor; waiting an adjustable predeterminedtime and starting the liquid refrigerant pump.
 8. The method of claim 7wherein the controller is capable of monitoring the compressor dischargepressure measuring device to maintain the desired head pressure byadjusting the speed of the condenser fans.
 9. A method for cooling oneor more parts of a building or processes comprising the steps of:providing a controller, a compressor, a condenser having an inlet and anoutlet and being cooled by a plurality of condenser fans, a receiver, aliquid refrigerant pump, an expansion device, an evaporator, theevaporator being surrounded by a chiller barrel having a cooled waterreturn and a chilled water supply line, and refrigerant lineinterconnecting the compressor, condenser, expansion device andevaporator in series, in a closed loop for circulating refrigeranttherethrough; providing a condenser inlet refrigerant temperature sensorat the condenser inlet and a condenser outlet temperature sensor at thecondenser outlet in electronic communication with the controller;providing a first compressor input ball valve in the refrigerant linebetween the evaporator and the compressor; providing a second compressordischarge ball valve in the discharge line of the compressor to isolatethe compressor; providing a compressor bypass line for the refrigerantto bypass the compressor having a third compressor bypass ball valve;providing a fourth expansion line ball valve upstream of the expansiondevice; providing an expansion device bypass line and a fifth expansiondevice bypass ball valve, monitoring the coolant requirements of thebuilding or processes to determine when free cooling is appropriate;providing a digital controller in electronic communication with each ofthe ball valves, the digital controller being capable of switching thesystem to free cooling mode by; closing the compressor input ball valveand the compressor discharge ball valve to bypass the compressor;turning off the compressor crankcase heater; opening the compressorbypass ball valve; opening the expansion bypass ball valve to bypass theexpansion device; closing the expansion line ball valve; soft startingthe liquid refrigerant pump; and increasing or decreasing the speed ofthe condenser fans to maintain a specific condenser output temperature.10. The method of claim 9 further comprising the step of deactivatingthe liquid refrigerant pump and the condensing fans when the chilledwater supply temperature reaches a predetermined set point.
 11. Themethod of claim 9 wherein a receiver is installed following thecondenser, the receiver being installed lower that the outlet of thecondenser thereby serving as a vapor trap and draining liquidrefrigerant from the condenser.
 12. The method of claim 9 wherein thecontroller is capable of switching to mechanical cooling when requiredby closing the expansion device bypass ball valve; opening the expansiondevice line ball valve; starting the condenser fans; waiting anadjustable predetermined time for refrigerant in the evaporator to boiloff; opening the compressor input ball valve and the compressordischarge ball valve; closing the compressor bypass ball valve; startingthe compressor; waiting an adjustable predetermined time and startingthe liquid refrigerant pump.
 13. The method of claim 12 wherein thecontroller is capable of monitoring the compressor discharge pressuringmeasuring device to maintain the desired head pressure by adjusting thespeed of the condenser fans.
 14. A system for cooling one or more partsof a building and or processes comprising: a compressor, a condenserhaving an inlet and an outlet and a plurality of condenser cooling fans,a receiver, a liquid refrigerant pump, an expansion device, anevaporator, the evaporator being surrounded by a chiller barrel having acooled water return and a chilled water supply line, and refrigerantline means interconnecting the compressor, condenser, expansion deviceand evaporator in series, in a closed loop for circulating refrigeranttherethrough; a compressor input line ball valve and a compressordischarge line ball valve; a compressor bypass line for the refrigerantto bypass the compressor input line ball valve, the compressor and thecompressor discharge line ball valve, the compressor bypass line havinga compressor bypass line ball valve; an expansion device ball valvepreceding the expansion device; a expansion device bypass line for therefrigerant to bypass the expansion device and the expansion device ballvalve, the expansion device bypass line having an expansion devicebypass ball valve; a controller in electronic communication with theball valves, the controller being capable of switching between freecooling and mechanical cooling modes when desired and floating the headpressure mechanical cooling modes, the controller also being capable ofvarying the flow of liquid refrigerant in free cooling mode.
 15. Thecooling system of claim 14 further comprising a condenser inletrefrigerant temperature sensor at the condenser inlet and a condenseroutlet temperature sensor at the condenser outlet in electroniccommunication with the controller.
 16. The cooling system of claim 15wherein the controller monitors the condenser inlet temperature and thecondenser outlet temperature and is capable of varying the speed of thecondenser fans to maintain a specific condenser output temperature. 17.The cooling system of claim 16 further comprising a compressor dischargepressure measuring device for measuring head pressure the pressuremeasuring device being in electronic communication with the controller.18. The cooling system of claim 17 wherein when the controller switchesto free cooling mode, the controller sends a signal to turn off thecompressor crank case heater, close the compressor input line ballvalve, close the compressor discharge line ball valve, open thecompressor bypass line ball valve, open the expansion device bypass ballvalve, close the expansion device line ball valve and soft start theliquid refrigerant pump.
 19. The cooling system of claim 14 wherein thecontroller is capable of deactivating the liquid refrigerant pump andthe condensing fans when the chilled water supply temperature reaches apredetermined set point.
 20. The cooling system of claim 14 wherein thecontroller is capable of switching to mechanical cooling, when required,via electronic communication to turn on the compressor crankcase heater,close the expansion device bypass ball valve; open the expansion deviceline ball valve; start the condenser fans; wait an adjustablepredetermined time for refrigerant in the evaporator to boil off; openthe compressor input ball valve and the compressor discharge ball valve;close the compressor bypass ball valve; start the compressor; wait anadjustable predetermined time and soft start the liquid refrigerantpump.
 21. The cooling system of claim 17 wherein the controller iscapable of monitoring the compressor discharge pressure measuring deviceto maintain the desired head pressure by adjusting the speed of thecondenser fans.